Hydrocarbon conversion



March 19, v1946. H. J. PAsslNo HYDROGARBON CONVERSION original Filed May 51, 1941 matic hydrocarbons with ethylene. v ticularly, the invention relates to the ethylation ably this ratio should Patented a. 1o, 194s HYDROCARBON CONVERSION Herbert J. Pas'sino, Englewood, N. J., assignor to The M. W. Kellogg Company, Jersey City, N. J., a corporation of Delaware Original application May 31, 1941, Serial No. 395,973. Divided and this application May 1, 1945, Serial No. 591,273

s claims. (ci. 26o-67.1) 'I'his invention relates to the ethylation of aro- More parof relatively low-boiling aromatic hydrocarbons such as benzene, toluene and the xylenes with ethylene in the presence of a catalyst essentially consisting of hydrogen iiuoride.

While. the catalyst employed in my invention,

consists essentially of hydrogen fluoride, minor amounts of other materials may be employed in connection with the hydrogen uoride as promoter therefor such as small amounts of boron fluoride or nickel. I prefer to carry out the proc# ess under conditions of temperature and pressure under which the hydrogen fluoride is in the liquid state although the vuse of hydrogen fluoride in the vapor form is not excluded from the scope of the invention.

In carrying out my invention an aromatic hydrocarbon, or a mixture of aromatic hydrocarbons,or a mixture of hydrocarbons containing an aromatic hydrocarbon to be ethylated, isintimately contacted with ethylene'and hydrogen fluoride at a temperature not substantially lower than 50 F. and under a pressure not substantially lower than 200 pounds per square inch for a time sullicient to eifect the desired ethylation.

While the foregoing temperatures and pressures 'represent substantially minimum values, higher temperatures and higher pressures may be employed with advantage. The maximum permis- C Tl hydrocarbons which are present should be maintained to permit intimate mixing and dispersion of the hydrocarbons and hydrogen iiuoride.A

Suitably, the reaction may be carried out by intimately contacting gaseous ethylene with a, mixture of liquid hydrocarbons containing the aromatic hydrocarbon to be ethylated and hydrogen uorlde. Conveniently, the reaction isV carried out in the liquid phase in a continuous manner in which a body of emulsion of liquid hydrocarbons and hydrogen fluoride is maintained in 'contact with ethylene. A portion of this body of emulsion is withdrawn continuously for recovery of ethylated product, and fresh supplies of hydrocarbon reactants are added continuously to the reaction zone in the proportions necessary to maintain the desired molar of aromatic hydrocarbons to ethylene. The hydrocarbons Withdrawn from the reactionzone are fractionated if desired to separate fractions suitable for recycling and fractions containing the ethylated product.

The hydrocarbons withdrawn from the reaction zone may be substantially separated from l hydrogen fluoride prior to withdrawal, or a mixsible temperature is governed by the tendency of the ethylene to po1ymerize,but it is found that temperatures up to 200 F. may be employed with advantage. The maximum permissible pressure also is affected by the tendency of the ethylene to po1ymerize.although this effect is probably not so noticeable as in connection with the use of high temperatures. Pressures up to 3000 pounds per square inch may be employed without excessive polymerization of ethylene, although the use of higher pressures is not excluded from the scope of my invention. Inasmuch as the speed of the desiredy reaction is promoted by high temperature and especially by high pressure, it is desirable to employ as high a. pressure and as high a temperature as is practical or permissible.

It is desirable also to maintain the molar ratio of aromatic reactants to ethylene in the reaction zone not substantially lower than 1:1, and pref=Il be at least 10:1.

The quantity of hydrogen iiuoride which should be used in relation to the quantities of hydrocarbons in the reaction zone is not critical, but a sumclent volume in relation to the volume of turev of catalyst and hydrocarbons may be withdrawn from thereaction zone. Such a mixture is separated by settling and -vdrawing oif the supernatant hydrocarbon layer, leaving the hydrogen iiuorideto be recycled to the reaction zone. The hydrocarbons. withdrawn vfrom the reaction zone are fractionated ifl desired to separate fractions suitable for recycling and fractions containing the ethylated product. The ethylate may if desired be neutralized with a caustic solution to effect removal loi residual amounts of hydrogen fluoride. Hydrogen fluoride withdrawn from the reaction zone is replaced by the continuous or Periodical addition to the reaction zone of recycled or freshV hydrogen fluoride.

The' invention will be described further by reference to examples of the application of the process to the ethylation of benzene. It is to be understood, however, that the invention is not lim-V ited by reference to the ethylation of benzene but includes within its .scope the treatment of any suitable aromatic hydrocarbon, particularly lowboiling aromatic hydrocarbons such as benzene. toluene and the xylenes.

, Example I Benzene, hydrogen duoride. vand ethylene were I charged to a shaker bomb at a pressure of 500 pounds. The hydrogen uoride was equivalent to approximately 12 per cent of the benzene, and

the molar ratio of benzene to vethylene was approximately 2:1. However, since only a part of the ethylene in the bomb was contained in the benzene-hydrogen iiuoride mixture the molar ratio of benzene to ethylene in the liquid mixture was substantially higher than 2:1. The mixture was agitated at a temperature of rl to 80 F. for

` a period of 16 hours during which time the pressure on the bomb declined from the initial pres- 'sure of l500 pounds to a iinal pressure or 200 pounds. The liquid products were separated by distillation to recover anK ethyl benzene product equivalent to approximately l0 weight per cent of the benzene charged and equivalent to a con-- .Suchhigh-boiling products may be separated from the hydrocarbon product by fractionation Feed Run No. l Run No. 2

' F. F. F. Initial boiling pont 90 108 S6 1 oil at; 119 137 124 50 0C at 157 166 162 g oil at 187 245 294 y End boiling point 212 523 489 andv returned to the reaction zone for conversion to the desired ethylated hydrocarbon by dealkylationv reactions. For example, in the ethylation of benzene the ethylate may be fractionated to separate hydrocarbons higher boiling than ethyl benzene (e. g. diethyl'benzenes), and theA latter may be recycled to the reaction zone for conversion to ethyl benzene.'

Example I! A light napitha containing 1s per cent benzene was subjected to ethylation in accordance with the present invention in two test runs.

In run No. 1 a mixture of the light naphtha,

hydrogen fluoride and ethylene was charged to a shaker bomb at a pressure of 850 pounds. The quantity of ethylene charged to the shaker bomb produced a pressure of 210 pounds persquare inch. and nitrogen was charged to the bomb to produce the operating pressure of 850 pounds per square inch. The hydrogen iluoride was equivalent to approximately 15 weight per cent of the light naphtha. The molar of benzene to ethylene in the bomb was between 1:1 and 2:1, but a substantially higher ratio existed in the liquid mixture containing the catalyst. In this run the reaction mixture was maintained with agitation at a temperature of '70 to 80 F. for a contact time of 2.5 hours during which time the pressure declined to a final pressure of 530 pounds per square inch.

In run No. 2 a mixture of a light naphtha, hy-

' drogen fluoride and ethylene was charged to a shaker bomb at a. pressure of 810 pounds. The hydrogen fluoride present in the bomb was equivalent to approximately 15 weight per cent oi the light naphtha. The molar ratio of the benzene to ethylene in the bomb was approximately 3:5, but since only a part of the ethylene present in the'bomb was contained in the liquid mixture of the catalyst and naphtha the ratio of benzene to ethylene in the liquid mitxure was substantially higher than 2:1. The mixture was maintained with agitation at a temperature of ',80 to 85 F. during an operating run of three hours in.

which time the pressure on the bomb declined to a iinal pressure of 560 pounds per square inch.

Substantial ethylation or the benzene contained in the light naphtha in these two runs is indicated by a comparison of the A. S. T. M. distillation analyses of the liquid' products oi the light naphtha, which were as follows:

- Sary The invention will be described further by reference, for purpose of illustration, to the accompanying drawing which is a diagrammatic view in elevation of an embodiment of an apparatus suitable for carrying out the new process.

Referring to the drawing, a substantially liquid mixture of hydrogen iiuoride, a hydrocarbon liquid containing a substantial proportion of an aromatic hydrocarbon to be ethylated, and ethylene are maintained in reactor l. The mixture is continuously agitated by any suitable means to eilect intimate mixing of the reactants and hydrogen uoride, which results in the formation of an emulsion of the liquid hydrocarbons and hydrogeniiuoride. Conveniently, agitation is effected by'wlthdrawing a portion of the mixture from the upper part o! reactor i as through collecting means 2 and recirculating the mixture thus withdrawn through line 3 into distributing element 4 located in the lower portion of reactor I. Line 3 is provided with a pump', and dis- A reactants and catalyst is effected. In operations at relatively low temperature the heat developed by the exothermic ethylation reaction may necessitate the provision of means for cooling the reaction mixture to maintain the reaction temperature at the desired level. To eiiect such cooling any suitable means for refrlgerating the reaction mixture by indirect heat exchange may be provided. Conveniently, cooling is eiected by passing the mixture circulated through line 3 through coolingmeans 6 located preferably in line I between pump 6 and distributing element l. In operations at higher temperatures simpler means may be suiiicient to cool the reaction mixture to the necessary degree, and it may be necesy to supply heat to maintain a desired relatively high reaction temperature.

Aromatic hydrocarbons are introduced into the system through line 1 provided with a pump 8.

from which the aromatic hydrocarbons are withdrawn through line I0 provided with pump Il.

Line I0 connectswith line 3 whereby material.

passing therethrough is introduced into reactor I through the iets described above. Alternatively, the aromatic hydrocarbons introduced into the system through line 1 may be introduced directly into line I. For this purpose a separate line I2 is provided which connects line 1 directly with line 3. f

Ethylene to be employed in the process is introduced into the system through line I3 .provided with a compressor il. Line i3 connects with reed preparation drum 8 whereby ethylene thus introduced is brought into intimate contact with the aromatic hydrocarbons in drum 9 by any suitable gas and liquid contact means. Ethylene is thus introduced into reed preparationdrum 'l vinA an.

dissolve in the liquid hydrocarbons 'in drum 9 depends upon the pressure maintained thereon by pump 8 and compressor I4. By controlling this pressure the quantity of ethylene passed to reactor I through line I may be controlled. Alternatively, ethylene may be introduced directly into through lines I0; I2 and I5 is withdrawn continuously from reactor I through line I6. Pref` erably, the point of withdrawal of reaction mixture through line I3 is located somewhat above the collecting means 2 lwhereby preliminary separation of hydrogen fluoride from the hydrocarbon phase of the emulsion may be effected in the portion of the reactor above collecting means 2. By

this means the material withdrawn through line I6 contains a substantially smaller proportion of hydrogen fluoride than the mixture in the reactor` as a whole, thus reducing the amount of hydrogen fluoride which must be recycled.

The reaction mixture withdrawn through line 4I6 is introduced at reduced pressure into a separator I'I. In separator Il ethylene absorbed in the reaction mixture is separated and withdrawn overhead through line I8 which may connect with line I3 for recycling ethylene thus obtained to the process. Separator Il also may function as a settier whereby any hydrogen uoride introduced therein as part of the mixture collects in the lower portion thereof. `Hydrogen fluoride thus separated is withdrawn through line I9 which is provided with a pump 23 and connects with line 3 for recycling this hydrogen fluoride to the reaction zone. The liquid hydrocarbon content of the mixture in separator I1 collects as an upper 'phase and is withdrawn through line 2I through.

which this material, containing the ethylate product of the process, may be withdrawn from the system. Preferably, however, all or a portion of this material is diverted through line 22 which connects with a fractionator 23.

Fractionator 23 is operated to separate a condensate higher boiling than the charge material and containing the ethylate product of theprocess. Thelower-boiling materials, including un-V reacted aromatic hydrocarbons and any accom panying non-aromatic constituents of the charge, are withdrawn overhead as a vapor through line 24 which connects to a drum 25. Line 23 is' provided with cooling means 26 to effect condensation of the hydrocarbons, which are collected in drum 25. Drum 23 is provided with a gas outlet 21 for removal of any ethylene separated in drum 25. Material withdrawn through line 21 may be removed from the system or recycled t'o the reaction zone as desired. The condensate collected in drum 25 is withdrawn therefrom through line 28 provided witha pump 29. A portion of' thiscondensate is diverted through line 30 for introduced therein, a substantial quantity of aromatic v hydrocarbons is recycled through line 2.8. Alternatively, material'thus recycled may be introduced directly into line 3.' For this purpose line 30 is provided to connect line 28 directly with line 3.

-The condensate collected in fractionator 23, containing the ethylate. product of lthe process, is withdrawn through line 3|, through which line vit may be withdrawn from the process. Preferably,vhowever, all or a portion of this condensate is diverted from line 3i through line 32 which connects with a second fractionator 33.

Fractionator 33 is operated under conditions of temperature and pressure effective to separate the ethylate .product in anyxdesired manner. For example, in the ethylation of benzene fractionator 33 may be operated under conditions effective i ductioninto the top of fractionator 23 as reux.

to separate as a condensate hydrocarbons higher boiling than ethyl benzene such as diethyl benzene. a separate product of the process it is advantageous to recycle them to` the reaction zone for conversion to the lower-boiling ethylatearomatic hydrocarbon by disproportionation reactions such as de-ethylation. For this purpose line 35, provided with pump 36, is provided to connect line 34 with line 'I. Alternatively, high-boiling materials thus recycled may be introduced directly into line 3. For this purpose line 37 is provided to connect line .35 to line 3. p

The lower-boiling ethylate product of the process is separated in fractionator 33 as a vapor and withdrawn therefrom through line 38 which conl nects .with drum 39. Line 33 is provided with ment such as a caustic wash toremove residual quantities of hydrogen fluoride which may remain therein.

' A portion of the reaction mixture circulating ythrough line I3 to line 3 may be withdrawn by means not shown to a settler from which the hydrocarbon phase is returned to line 3. The' hydrogen fluoride separated in the settlermay be withdrawn from the process or may be subjected to reviviiication treatment.

To replace hydrogen fluoride lost or withdrawn from the process line M provlded'with pump 45 is provided for the introduction of fresh hydrogen fluoride into line I9 and therebyinto line 3.

Instead of a. reaction chamber of the general type illustrated in the drawing the liquidv re' actants may be contacted by anyother suitable means. For example, the liquid mixture may be passed through an elongated reaction zone of restricted cross-sectional area such as a pipe coil. the velocity of flow being relied upon to maintain the mixture. The use of a pipe coil is particularly advantageous in carrying out the reaction under vapor phase conditions.

- In liquid phase operations it isfeasible to dissolve in the reaction mixture the quantity of ethylene required. However, mixed phase operations wherein ethylene is present in the reaction zone as a. gas are within the scope of the invenf tion. v

This application is a division of application Serial No. 395,973, tiled May 31. 1941.

While these materials may constitute 4 @scacco I claim: f

1. A process for converting a polyalkyl aromatic hydrocarbon to an alkyl aromatic hydrocarbon having va fewer number of alkyl groups per molecule, which comprises treating a polyalkyl aromatic hydrocarbon in admixture with a substantial molecular excess of an aromatic hydrocarbon having at least two alkyl groups per molecule fewer than said polyalkyl aromatic hydrocarbon and in the presence of hydroiiuoric acid as the effective catalyst to produce an alkyl aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatic hydrocarbon, and recovering from eiliuents of said treatment an alkyl aromatic hydrocarbon so produced.

2. A process for converting a polyalkyl aromatic hydrocarbon to an alkyl aromatic hydrocarbon 'having a fewer number of alkyl groups per molematic hydrocarbon in admixture with a substantial molecular excess of an aromatic hydrocarbon having at least two alkyl groups per molecule fewer than said polyalkyl aromatic hydrocarbon and in the presence of hydrofluoric acid as the effective catalyst and a small amount of a nickel promoter to produce an alkyl aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatic hydrocarbon, and recovering from efiiuents of said treatment an alkyl aromatic hydrocarbon'so produced.

3. A process for converting a'polyalkyl aromatic hydrocarbon to' an alkyl aromatic hydrocarbon having a fewer number of alkyl groups per molecule, which comprises treating a polyalkyl aromatic hydrocarbon in admlxture with a substantial molecular excess of an aromatic hydrocarbon having at least two alkyl groups per molecule fewer than said polyalkyl aromatic hydrocarbon and in the presence of liquid hydroiluoric acid as the eiective catalyst to produce an alkyl aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatic hydrocarbon, and recovering from eilluents of said treatment an alkyl aromatic hydrocarbon so produced.

4. A process for converting a polyalkyl aromatic hydrocarbon to an alkyl aromatic hydrocarbon having a fewer number of alkyl groups per molecule, whichcomprises treating a polyalkyl aromatic hydrocarbon in admixture with a substantial molecular excess of an aromatic hydrocarbon having at least two alkyl groups per molecule fewer than said polyalkyl aromatic hydrocarbon at a temperature not substantially lower than 50 F. and in the presence of hydrofluoric acid as the eective catalyst to produce an alkyl cule, which comprises treating a polyalkylaro- 'aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatic hydrocarbon, and recovering from eiiiuents of said treatment an alkyl aromatic hydrocarbon so produced.

5. A process for converting a polyalkyl aromatic hydrocarbon to an alkyl' aromatic' hydrocarbon having a fewer number of alkyl groups per molecule, which comprises treating a polyalkyl aromatic hydrocarbon in admixture with a substantial molecular excess of an aromatic hydrocarbon having at least two alkyl groups per molecule fewer than said polyalkyl aromatic hydrocarbon under a pressure not substantially lower than 200 pounds per square inch and in the presence of hydrouoric acid as the eective catalyst to produce an alkyl aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatichydrocarbcn, and recovering from enluents of said treatment an alkyl aromatic hydrocarbon so produced.

6. A process for converting a polyalkyl aromatic hydrocarbon to an alkyl aromatic hydrocarbon having a fewer number of alkyl groups per molecule, which comprises treating a polyalkyl aromatic hydrocarbon in admixture with a substantial molecular excess of benzene and in the presence of hydroiluoric acid as the effective catalyst to produce an alkyl aromatic hydrocarbon having fewer alkyl groups per molecule than said polyalkyl aromatic hydrocarbon, and recovering from eiiluents of said treatment an alkyl aromatic hydrocarbon so produced.

7. A process for converting a poly-ethyl benzene to an ethyl benzene having a fewer number of ethyl groups per molecule, which comprises treating a poly-ethyl benzene in admixture with a `substantial molecular excess of an aromatic hydrocarbon having at least two ethyl groups per molecule fewer than said poly-ethyl benzene and in the presence of hydrofiuoric acid as the effective catalyst to produce an ethyl benzene having fewer ethyl groups per molecule than said polyethyl benzene, and recovering from eilluents of said treatment an ethyl benzene hydrocarbon so produced. s

8. A process for converting a poly-ethyl benzene to mono-ethyl benzene which comprises treating a poly-ethyl benzene in admixture with a substantial molecular excess of benzene and in the presence of hydrofluoric acid as the effective catalyst to produce mono-ethyl benzene. and recovering from efiluents of said treatment monoethyl benzene so produced.

HERBERT J. PASSING. y 

